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Discussion Starter · #1 ·
I took a piece of 1/8" plexiglas and used my router (along with the router guide from rockler). The template turned out perfect. I cannot get a good clean cut however. My router edge get stuck on the corners of the oposite side of the "X". I often over-shoot the edges.

Should I used thicker plexiglas? I though about using a larger router base, this would float over the entire template.

I have been using double-stick tape to hold down my piece I am cutting. I drilled/counter sunk four holes on the template, to secure with screws.

Any suggestions?
 

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Let me see if I understand what you are doing. You cut a template from some material and are using it with a guide bushing to cut out an "X" shape from 1/8" plexiglass? Or are you making an "X" shaped cut out in 1/8" plexiglass? More detailed info please.
 

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To my way of thinking the easiest way to do this job is with your router mounted in a router table. I would use a 1/4" straight bit with a bearing on the end. These bits are called flush trim bits and are commonly used for trimming Formica or veneer on cabinets. Fasten your template to your MDF, rough cut it to shape using a jig saw if possible. Adjust your bit height above the table so the bearing rides on the template with the MDF on the bottom. Slowly bring your template onto the bearing and then move it around in a counter clockwise direction. You will have excellent control, easily see where your cuts are and get a nice smooth finish.
 

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Discussion Starter · #6 ·
My template is a 8" X 10" plexiglas rectangle. The "X" is cut out in the center of this. My "X" is about 5". If I understand what you are stating - make a template that is an "X", not a template with a "X" cutout of it - correct?
 

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mcbradford said:
I'm sorry but I am having trouble understanding what you have done and what you are trying to do.

Let me see if I'm at least close. You started with a piece of plexiglas and used that to make a template. The template looks like a square/rectangle with a "X" cut out of it. This "X" is what you now want to run a guide bushing in and the bit will cut the shape of an "X" into the finished project.

The 1/8" material is thinner then the guide bushing barrel height so now I'm really lost.... how do you keep the router sub-base on the template and have the bushing not touching the project material? Or is this where the problem starts? If this is what is happening then what you need to do is find out how long the barrel of the template guide is then use some material cut to ruffly the shape of the "X" but larger and it does not need to be accurate. Attach this material to the template you have made... to the under side would be best. I might be way off on what you are asking so I will not continue but if I am on track and you need more information post again and I'll finish the story.

I took a piece of 1/8" plexiglas and used my router (along with the router guide from rockler). The template turned out perfect. I cannot get a good clean cut however. My router edge get stuck on the corners of the oposite side of the "X". I often over-shoot the edges.

Should I used thicker plexiglas? I though about using a larger router base, this would float over the entire template.

I have been using double-stick tape to hold down my piece I am cutting. I drilled/counter sunk four holes on the template, to secure with screws.

Any suggestions?
I hope this helps,

Ed
 

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Discussion Starter · #8 ·
Thanks for the help. I was wanting to prevent cutting another template - but now I am glad I did. I cut another "X" out of 1/4" plexiglas - double-stick taped it to the mdf. Used my fixed router on the router table with a 1/4" straight bit with a bearing on the end. Perfect cut everytime and I can now see what I am doing with much better control.

Thanks for all the help.
 

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I'm glad my idea helped. When you finish your project post a photo for us to see.
 

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Very nice!

You do know that if you spoil your kids with nice stuff like now that then they will expect a nice hand crafted car when they get to be 16 or 18..... a heck of a job to do with a router......

Here is a short cut to the picture:

(broken link removed from this location)

Thanks for sharing!

Ed
 
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